Foot cushioning device



Feb. 23, 1965 w. M. SCHOLL 3,170,250

FOOT' CUSHIONING DEVICE Original Fil-ed June 22, 1962 2 SheetsSheet 1 I N VENTOR.

3y W V WAFERNEYS Feb. 23, 1965 w. M. SCHOLL FOOT cusuxoumc DEVICE 2 Sheets-Sheet 2 Original Filed June 22 INVENTOR.

M ATTORNEYS finished article.

.' EGGTQUSHHQNINGDEVEQE a William.M.i Scholl, 213 W: .SchillenSt, Chicago, Ill. Uriginal application .lune 22,1962, Sei'. 'la o'. M34359. Divided and this applicationMay 11, lfifi lgfier. No.

366,430 r t i ltl \Clairnsr (Ql. 36- --44) This invention relates to improvements in afoot cushioning device,..and' more particularly to a device of the Insole, filedlune 22,1962, Serial No. 204,359,,which cos ijendingparent application is, in turn a continuation-impart of an application entitled Insole-and of Maliing. the Same]? filed June ll, l953, flSe'rial'lJo. 741,378,

now ahanclonedffhe copending parent application-now contains claims] directedto the niethod ,o flmaliing the instant invention.

.Uflitsdstates Patent iiyll'hi hf Patented Febt 23, 1965 size, then stacking thern, putting-ontheholding means, and then the tedious operation .with the heated tool results in a'device also prohibitively expensive where competition isto be'inet. 'In other instances, abinding was placed aroundthe raw edges of precut stacked blanks,- I and such is definitely not desired in a heat seal product;

With the foregoing in mind; it is an 'inipoitant object of the instant invention to provide a multi-layer foot appliance which. may be formed in a single operation with an electronic die from stackedfstock layers of indefinite 'size, and wherein at least theupper and lower layers are heat sealed together in a bounding searn,5and with at least one of the layers of an open-nieshvfabric woven oftherrnoplastic filaments, the device having a smooth'and, .evenas Well as relatively fine'heatsealrseam. v

Another object of the invention 'is theprovision of .a foot alleviating or cushioning. device. which may be formed ina'single' operation With an" electronic die, which may embody several layers ofmaterial, some ofwhich may be an open-mesh fabric woven of thermoplasticstrands, but

' wherein the heat'seal seanrun'iting'the Lla'yersis externally smooth, requires no further or additional: efforts to i l f It has become-desirable n many instance to, make foot cushioning-and alleviating appliancesand devices in t liefiformiof insoles, metatarsal lift's,= a-rch. lifts, 'and in various other forms; including various types ofisurgical 1 pads, by utilizing .layei s of thermoplastic; rnaterial lheat sealed together. Theheatsealing iusu ally embodies the.

establishment ofa $58,111 defining the bounding'fedge of the device, although various types of liftsa nd inserts ing heat sealedito one or more of 'thelayersgor trapped in;positio'n as inay be desired. fInthe maltin'gof devices of this, charactenfihereare ti'rnes when it is: de s'ired'to incorporate; one or nioife layers of openrhesh -fabric woven oftherrnoplastic strands of; filaments, .so'rnewhat in, the nature of .aifiy screen,but:;establisliing"'abounding H may be includedat intermediate points anchored by he I attain that smoothness, and is devoid of any'iunevenn'ess, notwithstandingi'the number of layers of open-mesh fab-v ricernbodied in the device. V A further object of this invention is theprovisliohof a foot alleviating or corrective device comprising'a plu'' rality of layers of thermoplasticmaterial,the, next outer most layer being-an open-mesh fabric woveniofthermo plastiostrandaand the outer or;1cover'layer.being a thin, thermoplasticfilm less tear resistant than'thezotherlay I ers, and'with a heat seal seam uniting the layers defining the bounding -edge of the device, and also-defining a tear; ill'iQlllSld. the seam for the "thin, cover filrmonly, whereby that sfilrn may be selectively. removed. at anytime by thenser of the device." 1 'fitill-another importantobject of the instant invention 1 is the provision of a foot cushioningor alleviating device J made upot. a plurality of layers of air peryioujsi thermo plasticmateriahwviththeoutermost layer on at least one 1 sideof the devicecomprisingathinair imperviousather- I inoplastic filrn. less tear resistant than; the-inner;layers,

, there beingaa, heat seal seam joining'all the layersand edge fine line heat and tearsealsearn in material of'thatkind with the 'useo'f a die in ahightreq iency electronic press, resulted in leaving exposed' endso-f'the 'thernio' plastic "filaments at the boundingj edge of the] finished product renderingthat edge somewhat saw-tooth in character, highly irritating to the user, especially. ifthe exposed portion ot a filamentbecamebentoutof its'reguposition. Inany event, withtheelectronic die heat sealingp'rocesa; it was virtually impossible to provide a fine snio'oth edge at the heat seal: seam that would not irritate the" foot of the useror injurethe article' of footwear,, and attlie-sarne ti-rne provide a-tear sal'fse am' whereby the waste could be easily removed from the ln' th epast, insoles ;en rbo'dying}a" plurality of layers I of open rnesh fabric woven frorn thermopla stic filaments heat sealed togetherslaround the bounding edge of the device have been made; Howevenfwhere dies' were used to unite such layers in" the prior manufacture, in order to establish a heat seal seam it was necessary'to employ two different press operations, thereby rendering the fin ished'product prohibitively expensive for usualtrade cornp'et-ition; Another-method heretofore employed for'unit-r ing the edgesof such open-mesh fabriclayers required the precutting of blanks to substantially the 'desired'size, stackingfthe blanks,- holding them in a templetor the like,

a and then passing entirely, around' the bounding edge of thedevice witha heatedtool to elirninate theraw 'edges and provide a heat-seal-fsearn. Precutting' the pieces to i of this invention;

defining thebounding edge oil-the device, and thej thin plastic-film being removable whenever-desired by tearing it from the appliance along the inside of thegheat seal" 7 seam, whereby the user of the device n' ay selectivelyrn: der tne device ventilative in character if so desired.

Q-It isanother object, of this invention toiprovide a foot cushioning. device'cornprising a plurality of -layers," of-j which the outer layer on each side of theideviceis athin thermoplastic filrn, less tear-resistant thanthe inner lay I ers, all of the layers being joinedxby aheat-seal seam de-f fining-the bounding edge of the-device andiazteardine, for

the removal of the thin coverlayers inside the seam, and

manner of removal; l V 1 While some of the more salient features, characteristics and advantages of the instant invention-have been above the'c'over layers-bearing indicia thereon directing the pointed out, others will become apparent-frorn -the fol-if lowing, disclosures, taken in conjunctionwiththe accompanying drawings, in which: a

FIGURE 1 is aplan view of aifoot cushioning device embodying irnprovements' of the instant invent-ion, with:

parts broken away to expose parts 'therebeneath', and'jwith,

the, original coyer layer removed, 1 1,

FIGUREZis a greatly enlarged transverse verticalseetio'nal view Of the structureof FIGURE. 1.;

FIGURE 3 .is a greatly enlarged, fragmentary vertical sectional andieitplod'ed viewillustrating the, various layers of device, embodying-principles going to make up one form FIGURE 4 is a greatly enlarged or magnified vertical sectional view through a device formed from the layers shown in FIGURE 3;

FIGURE 5 is a reduced fragmentary plan view of the structure of' FIGURE 4;

FIGURE 6 is the same view as FIGURE 5 but illustrating the removal of one of the film cover layers;

FIGURE 7 is a fragmentary plan view of a slightly different form of footcushioning device embodying principles of the instant invention;

Q FIGURE 8 is a greatly enlarged transverse vertical sectional view through the structure of FIGURE 7;

FIGURE 9 is a greatly enlarged transverse vertical sectional view through a foot alleviating or cushioning appliance of a still different form but embodying principles of this invention; and

FIGURE 10 is a view similar in character to FIGURE 9, but illustrating another form of construction.

As shown on the drawings;

While, as stated above, theinstant invention may be provided in various shapes, sizes, and thicknesses, for various specific purposes, by way of example and not by way of limitation, I have herein illustrated the device in th form of an insole.

In FIGURES l and 2 I have illustrated a foot cushioning device in the form of an insole as the same appears when the original'cover layers have been removed so as to provide both cushioning and aeration or ventilation.

The device in this form comprises a top layer 1 which is in the form of an open-mesh fabric woven of thermoplastic filaments; an intermediate and much thicker layer 2 of cushioning material, preferably thermoplastic, and a bottom layer 3 of the same material as the top layer 1. All these layers are heat sealed together around the bounding edge of the device by a thin and externally smooth heat seal seam as indicated at 4. i

The strands of the open-mesh layers 1 and 3 are ther-' moplastic that is capable of being commercially heat sealed by the electronic process. A number of materials are suitable for. this purpose, and by way of example it may be stated that satisfactory results have been obtained .by the use of a copolymer vinyl ester, vinylidene chloride,

polystyrene, and others, certain of which are mentioned in US. Letters Patent Nos. 2,160,931 and 2,495,045. The cushioning layer 2 may satisfactorily be a chemical foam such as a synthetic resin foam of the class including vinyl chloride foams, polyester foams, isocyanate foams, polyurethane foams and others which are satisfactory. Obviously, the open-mesh layers 1 and 3 permit the passage of air, and the same is true in connection with the foam layer 2 because that layer is cellular wth intercommunicating cells. Accordingly, when a device as shown in FIGURES 1 and 2 is worn it not only insulates thefoot against heat or cold, but it also permits a circulation of air adjacent the plantar surface of the foot by successive cornpressions and expansions during walking, giving pleasant and comfortable ventilation. Such a cushioning device as previously described may be had in any desirable colors, may be laundered at will, is extremely'quick drying, and is completely resistant to fungus, foot acids, perspiration and the like. It requires no special attention whatever and is extremely long lived. In the manufacture of the devices, stock sheets of in definite size are utilized so that many appliances or devices may be formed and severed from the respective sheets during the heat sealing process without the necessity of restacking any sheets and without the necessity of precutting individual blanks and the exercise of exceptional and tedious care in order to stack anclhandle individually cut blanks. In assembling the stock sheets in accord with the instant invention, the aforesaid sheets 1-, 2 and 3 are disposed in stacked order betweenupper and lower cover sheets 5 and 6, as seen clearly in FIGURE 3. The sheets 5 'and,6 are identical, and each is in the form of an extremely thin-thermoplastic film, such as an unsupported vinyl film or sheet, which is less dense and less tear resistant than any of the sheets or layers 1, 2 and 3. The sheets 5 and 6 are also air impervious and when they are in use the device is not ventilative.

After the stock sheets are stacked as indicated in FIG- URE 3, and it is of course understood that they will actually be lying one upon the other, a die preferably having the form or contour of the desired device is incorporated in an electronic heat sealing press and is brought down under pressure upon the superposed layers, whereupon a short charge of high frequency electric current is passed through the die, and the heat seal seam 4 is formed. At the same time the heat seal seam 4 is formed, a tear line is established immediately adjacent that seam permitting waste stock to be readily removed or stripped from the finished article around the outer edge of the seam. In the illustratedinstance all of the layers are incorporated in that heat seal seam, 'but as willlater appear herein the cushion layer need not be incorporated in the seam if layers above and below it are.

The thin films 5 and G during the making of the product provide additional thermoplastic material at the heat seal seam to fill up the interstices between the filaments and the fabric layers 1 and 3 so'that an externally smooth edged heat seal seam is provided. However, these films 5 and 6 perform an important function in thefinished product, namely that they give the ultimate user a choice as to whether he desires to keep them on the product or remove them. Due to less density of the material of the films 5 and 6, at the same time the heat seal seam is formed a tearline is established along theinner edge of this scam as indicated at 4a and 4b, respectively, in FIGURE 4.. Accordingly, the film'cover'layers 5 and 6 may be removed whenever desired. If ventilative devices or appliances areinitially requested the, films may beremoved by the manufacturer before delivery of the devices. However, if ventilative appliances are not demanded, the cover layers may remain in place and serve to maintain the article in a clean and sanitary condition as long as may be desired. It is preferable that each cover layer be provided with directions for its removal as shown in FIGURE 5 by printing or otherwise marking a tear line 7 across the respective film and putting a legend 8 adjacent the tear line telling how the cover layer may be removed. Should the user 'desire a ventilative appliance and wish to remove the-films 5 and 6, this may readily be done by disrupting a film in the region of line 7, by tearing, cut- 1 ting, orotherwise, and folding back the film as indicated by the flaps 9 and 10 in FIGURE 6 and stripping the entire film from the device along the inside of the heat seal sea-m 4.

It should be noted, however, that the customer or ultimate user is given a choice as to whether or not to use the cover films. If he does not wish his foot to contact directly the woven fabric layer, he may leave a cover film 5 or 6 in place. If he desies a non-ventilative appliance he may leave both cover films in place, if he desires to insulate his foot against wettness or dampness, he may leave one or both cover fil'rns in place, butif for any reason he desires to remove either or both cover films he can readily do so as explained above. With the cover films in place the device will appear as seen in FIGURES 4 and 5. With the cover films removed the device will appear as seen in FIGURES 1 and 2. Whether or not either or both films are removed, the heat seal seam 4 remains entirely smooth and even on its outer edge, is comfortable to the foot, will notinjure articles of footwear, and is smooth and even over its entire extent,rwherefore it is also extremely durable.

In FIGURES 7 and 8 I have illustrated a different form of the instant invention, wherein a foot cushion-' cover ,films and 6 above described and which remains as a permanent part of the finished appliance. This top layer 11 may be an'unsupported vinylsheet, and may be provided with numerous perforations 12 therein as I seen in FIGURE 7 if ventilation is desired. This form of the invention also includes a thick cushioning layer 13 whichimay be thesame as the previously described layer 2. Inthis instance the upper fabric layer 1 and the upper cover film 5 are not utilized. vHowever, the woven" fabric layer' 3 and the bottom cover film 6 are used in the same manner as previously described. The

layersare joined by a bounding heat seal seam 14 which, as stated above, is smooth and even. The lower cover film 6 may be left intact upon the device, or removed whenever desired, as explained above.

l In FIGURE-9 I have shown a form of the invention" which embodies all of the layersabove described in con nection with FIGURES 3- and 4, but in addition a cushless area than any of the other layers. The lift 15 may ion lift 15 is disposed 'between the upper open-mesh fabric sheet 1 and the foam cushioning layer 2 at sub-' stantially any desirable location, the lift 15 being of be a longitudinal arch"support, a' special heel seat, a

metatarsal arch lift, or any other desired form of lift, and may be of any suitable material, the same as the cushion layer 2, or of densermaterial if so desired. If

I the lift is of denser material it will stay in position'by virtue of being trapped by the other layers. If the lift is of a thermoplastic material, itlrnay be anchored in position by being heat sealed to the cushion layer 2 only, as indictaed' at 17 and it need not be secured to any of the other layers. I a a a In FIGURE 10 I have shown an embodimentof the invention made up of the same layers of material .de-

scribed in connection with FIGURES 7 and 8, but in this instance a lift 18 of lesser size than the other layers is disposed between the denser cover layer 11 at any Preferably the lift is of the same material as the cushion layer 13, but it may be of other desirable location.

material if desred. If it is of thenmoplastic material it can be anchored to the cover in the desired location by a bounding heat seal seam as indicated at 19 and it need i is permitted to individually restore itself to original condition and is not retracted by attachment or connection with another layer so that wrinkles or creaseswill not-be set into the structure during use. i

From the foregoing, it is apparent that I have provided a simple, economical, and highly durableform of foot cushioning or alleviating device which. provides theultimate user with a choice of -.having a ventilative device, a non-ventilative device, a choice of surfaces-for foot con-. tact, and a choice of having a device partially ventilative but one capable ofinsulating the foot against wetness or moisture. 1 v

It will be understood that modifications and variations I claim as my invention: I 1'. In a cushioning device, 7 j a first'layer of thermoplastic cushioning material,

a second layer of open-mesh fabric woven of thermo plastic filaments overlying one side of thefirst layer, a thin thermoplastic film less dense. than said layers :overthe exposed side of said fabric layer, and

i p a fine'line heat seal seam composed of the material of said layers and said film and defining the outline of the device, the, inner edge of said seamforming a" tear line for said film only.

7 may be effectedwithout departing from the scope of the 3 l novel concepts of the present invention. 5

2. In a cushioning layer, a

a first layer of thermoplastic cushioning material,

a second layer of open-mesh fabric woven of thermoplastic filamentsoverlying one side of the'first layer,

a thin thermoplastic filrnf more' easily torn than said layers over the exposed side of one of said layers,

and.

a are line heat seal seam bonding said l yers and said 'film and defining the outline of said device,

said film being "selectively 'r emovablefinside said seam.

3. In an insole, f A

a plurality of superposed layers of open-mesh fabric woven of thermoplastic filaments} a thin thermoplastic cover film less dense and more easily torn than said layers over the exposed face of and outermost layer, and

a fine line heat seal seam composed .of the material of said layers and bondingsaid layers and film together,

said film only beingremovable-inside said seam.

4. In a cushioning device,

a pair ofthin thermoplastic cover films, a pair oflayers'of open-mesh fabric woven of thermoplastic filaments between said films,

a layer of cushioning material between said fabric layers, and

a heat seal seam joining said fabric layers and films and defining the bounding edge of the device and a tear line inside the seam for said films only, said films being less dense and more easily torn than said layers.

5. In a cushioning device,

a layer ofthermoplastic cushioning material,

a sheet of open-mesh fabric woven'of thermoplastic filaments overlying said layer, I

a thin thermoplastic film less tear resistant than said layer and said sheet overlying said sheet,

a fine lineheat seal seam havinga smooth'outer edge of the material 'of said layer, sheet and composed and film, 1

' saidseam defining the outline of the device and a tear line inside the seam for said film only, and I indicia on said film directing its removal. Y 6. in a cushioning device,

a plurality of superposed layers of open mesh fabric woven of thermoplastic strands,

Itop and bottom thin thermoplastic cover films less tear I resistant than said layersdisposed'with said layers j therebetween, and

a heat seal seam joining said fabric layers and said films and defining the bounding edge of the device and a tear'line for each said film only inside said seam,

-whereby said films may seiectively be removed. 7. 'Inacushioning device, R l

v a plurality'of superposed layers of openernesh fabric woven of thermoplastic strands, 7

I i. stop andbottomthin thermoplastic cover films less tear resistant than said layers disposed with said layers therebetween,

a heat seal seam joining-said fabric layers andsaid films and defining the bounding edge ofthe device and a tear linefor each said filmonly inside said a I V n [whereby said films may selectively be removed,

T and indicia on each of said films directing the removal thereof. V 5

.8. In an insole, I

a plurality of superposed laers of open-mesh fabric woven of thermoplastic'filaments,

. a thin thermoplastic cover-film less dense .and more easily torn than said layers. over the exposed race of an outermost layer, and

.a fineline heat; seal seam composed ofthe materialiof 'saidlayers and film bonding said layers and film -a thin air impervious thermoplastic cover film less tear resistant than any of said layers and overlying the exposed face of an outermost layer, and

a heat seal seam joining said layers and said film and defining the bounding edge of the device and a tear line at the inside of said seam for said film only,

whereby. said film may be selectively removed.

10. In a foot cushioning device,

a layer of thermoplastic air pervious cushioning material,

a thin air impervious thermoplastic film less tear resistant than said layer over each side of said layer, and

a heat seal seam joining said layer and films and defining the bounding edge of the device and a tear line inside the seam for each of said films only,

- whereby said films render the device ventilative.

References Cited by the Examiner 'UNITED STATES PATENTS 9/46 High et al. 156538 X 8/47 Oestricher l565l5 9/49 Lindh 156-29O 1/50 Woodbury et al. 36-44 3/53 Gannonet al. 156380 11/53 Scholl.

8/57 Woskin et al. 156267 3/59 Hacklander 156l63 4/61 Scholl 3644 11/62 Williams 12146 1/ 63 Stickles 36-44 3/63 Midgley 12146 FOREIGN PATENTS 4/55 Great Britain.

JORDAN FRANKLIN, Primary Examiner. 

1. IN A CUSHIONING DEVICE, A FIRST LAYER OF THERMOPLASTIC CUSHIONING MATERIAL, A SECOND LAYER OF OPEN-MESH FABRIC WOVEN OF THERMOPLASTIC FILAMENTS OVERLYING ONE SIDE OF THE FIRST LAYER, A THIN THERMOPLASTIC FILM LESS DENSE THAN SAID LAYERS OVER THE EXPOSED SIDE OF SAID FABRIC LAYER, AND A FINE LINE HEAT SEAL SEAM COMPOSED OF THE MATERIAL OF SAID LAYERS AND SAID FILM AND DEFINING THE OUTLINE OF THE DEVICE, THE INNER EDGE OF SAID SEAM FORMING A TEAR LINE FOR SAID FILM ONLY. 